Rotor lock for wind turbine

ABSTRACT

A lock for preventing rotation of a rotor of a wind turbine has a rotatable lock pin, a pin support supportable in a nacelle of the wind turbine and a mechanism for rotating the lock pin. The pin support has a hub-facing face proximate a rotor hub. The rotatable lock pin is rotatably mounted on the pin support. The lock pin has a cammed portion extending away from the hub-facing face toward the hub. The lock pin inserted into a complementary rotor lock aperture on the rotor hub when the pin support is supported in the nacelle. Rotation of the lock pin causes engagement of an exterior surface of the cammed portion with an interior surface of the rotor lock aperture to immobilize the lock pin against the interior surface to prevent relative motion between the lock pin and the aperture to prevent rotation of the rotor.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. Ser. No. 17/271,334 filedFeb. 25, 2021, which is a national entry of PCT/CA2019/051174 filed Aug.27, 2019, which claims the benefit of United States Provisional PatentApplication U.S. Ser. No. 62/725,885 filed Aug. 31, 2018, the entirecontents of all of which are herein incorporated by reference.

FIELD

This application relates to wind turbines, in particular to a lock forpreventing rotation of a rotor during maintenance of the wind turbine.

BACKGROUND

Replacement or repair of wind turbine components, in particular windturbine components connected to a rotor of the wind turbine, isdifficult because the rotor may continue to rotate in the wind whileattempts are made to effect replacement or repair of the component.Components connected to a rotor include, for example, the main shaft,the gearbox, the generator and the like. To prevent the rotor fromrotating during replacement or repair of such components, the rotor maybe locked down to prevent rotation. However, different kinds of lockmechanisms have been used depending on the particular component to bereplaced or repaired because there are limited locations at which toeffectively mount a lock and existing locks are often mounted on thevery component that is desired to be replaced or repaired. Further, manyexisting locks are cumbersome or difficult to install and/or use.

There remains a need for a rotor lock that is easier to install and useand that can be used to lock a rotor irrespective of what turbinecomponent is to be replaced or repaired.

SUMMARY

In one aspect, there is provided a lock for preventing rotation of arotor of a wind turbine, the lock comprising: a pin support supportableon main bearing supports or main bearing support extensions in a nacelleof the wind turbine, the pin support comprising a beam and first andsecond clamps situated proximate ends of the beam, the clamps mountableon the main bearing supports or main bearing support extensions, thebeam comprising a hub-facing face proximate a rotor hub of the windturbine and a gearbox-facing face opposite the hub-facing face when thepin support is supported on the main bearing supports or main bearingsupport extensions, the beam further comprising support aperturesthrough the beam extending between the hub-facing face and agearbox-facing face; first and second rotatable lock pins insertedthrough the support apertures to rotatably mounted the lock pins on thepin support, each lock pin comprising a first cylindrical portion havinga first central axis rotatably mounted through one of the supportapertures and a cammed portion comprising a second cylindrical portionhaving a second central axis, the second cylindrical portion having asmaller diameter than the first cylindrical portion, the secondcylindrical portion extending from an end of the first cylindricalportion such that the first and second central axes are not colinear,the cammed portion protruding from and extending away from thehub-facing face of the pin support toward the hub, the first cylindricalportion protruding from the gearbox-facing face, the lock pins insertedinto complementary first and second rotor lock apertures, respectively,on the rotor hub when the pin support is supported on the main bearingsupports or main bearing support extensions; first and second lock pinbrackets, the first lock pin connected to the first bracket proximate afirst end of the first bracket, the second lock pin connected to thesecond bracket proximate a first end of the second bracket; and, aturnbuckle for rotating the lock pins, the turnbuckle comprising a frameand first and second ends, the first end of the turnbuckle connected tothe first bracket proximate a second end of the first bracket, thesecond end of the turnbuckle connected to the second bracket proximate asecond end of the second bracket, whereby rotation of the frame of theturnbuckle causes the second end of the first bracket and the second endof the second bracket to move arcuately thereby causing the first andsecond lock pins connected proximate the first ends of the first andsecond brackets to rotate so that exterior surfaces of the cammedportions engage with interior surfaces of the complementary apertures toapply forces in opposite directions at the interior surfaces of theapertures to immobilize the lock pins in the respective aperturesagainst the interior surfaces to prevent relative motion between thelock pins and the apertures to prevent rotation of the rotor.

In another aspect, there is provided a lock for preventing rotation of arotor of a wind turbine, the lock comprising: a pin support supportablein a nacelle of the wind turbine, the pin support having a hub-facingface proximate a rotor hub of the wind turbine when the pin support issupported in the nacelle; a rotatable lock pin rotatably mounted on thepin support, the lock pin having a cammed portion extending away fromthe hub-facing face of the pin support toward the hub, the lock pininserted into a complementary rotor lock aperture on the rotor hub whenthe pin support is supported in the nacelle, rotation of the lock pincausing engagement of an exterior surface of the cammed portion with aninterior surface of the aperture to immobilize the lock pin against theinterior surface of the aperture to prevent relative motion between thelock pin and the aperture to prevent rotation of the rotor; and, amechanism for rotating the lock pin.

In another aspect, there is provided a lock for preventing rotation of arotor of a wind turbine, the lock comprising: a pin support supportablein a nacelle of the wind turbine, the pin support having a hub-facingface proximate a rotor hub of the wind turbine when the pin support issupported in the nacelle; first and second rotatable lock pins rotatablymounted on the pin support, each of the lock pins having a cammedportion extending away from the hub-facing face of the pin supporttoward the hub, the lock pins inserted into complementary first andsecond rotor lock apertures, respectively, on the rotor hub when the pinsupport is supported in the nacelle, rotation of the lock pins causingengagement of exterior surfaces of the cammed portions with interiorsurfaces of the complementary apertures to immobilize the lock pinsagainst the interior surfaces of the apertures to prevent relativemotion between the lock pins and the apertures to prevent rotation ofthe rotor; and, a mechanism for rotating the lock pins.

Rotation of one or more cam-shaped pins fitted into one or morecomplementary rotor lock apertures on the rotor hub forces the one ormore cam-shaped pins into engagement with interior surfaces of theapertures to secure the rotor. The camming action effectively wedges thecam-shaped pins in the rotor lock apertures to prevent any play betweenthe pins and the apertures. In an embodiment, the rotor lock aperturesmay be existing rotor lock apertures on the rotor hub. In an embodiment,the one or more cam-shaped pins may be rotated by a turnbuckle,preferably one turnbuckle connected to two pins.

In an embodiment, the lock pin comprises a first cylindrical portionrotatably mounted through a support aperture in the pin support. Thefirst cylindrical portion has a first central axis. In an embodiment,the cammed portion of the lock pin is a second cylindrical portion ofthe lock pin. The second cylindrical portion has a second central axis.In an embodiment, the second cylindrical portion has a differentdiameter, preferably a smaller diameter, than the first cylindricalportion. In an embodiment, the second cylindrical portion extends froman end of the first cylindrical portion such that the first and secondcentral axes are not colinear. In an embodiment, the lock pin isrotatable about the first central axis, the second central axis rotatingabout the first central axis when the pin is rotated. In an embodiment,rotation of the lock pin about the first central axis causes the cammedportion, for example the second cylindrical portion, to move laterallyacross the rotor lock aperture to engage or disengage from the interiorsurface of the rotor lock aperture.

In an embodiment, the mechanism for rotating the lock pin comprises aturnbuckle. In an embodiment, the turnbuckle is linked to the lock pinsuch that rotation of a frame of the turnbuckle causes rotation of thelock pin. In an embodiment, the mechanism for rotating the lock pincomprises a lock pin bracket, the lock pin connected to the bracket. Inan embodiment, the lock pin is connected to the lock pin bracketproximate a first end of the bracket and the turnbuckle is connected tothe lock pin bracket proximate a second end of the bracket. In anembodiment, rotation of the frame of the turnbuckle causes the secondend of the bracket to move arcuately thereby causing the lock pinconnected proximate the first end of the bracket to rotate. In anembodiment, when the lock pin is rotated, the lock pin applies a forceon the interior surface of the rotor lock aperture to immobilize thelock pin the rotor lock aperture.

In an embodiment, the lock pin comprises first and second lock pins. Inan embodiment, the mechanism for rotating the lock pin comprises firstand second lock pin brackets. In an embodiment, the first lock pin isconnected to the first lock pin bracket proximate a first end of thefirst bracket. In an embodiment, the turnbuckle comprises a first endand a second end. In an embodiment, the first end of the turnbuckle isconnected to the first bracket proximate a second end of the firstbracket. In an embodiment, the second lock pin is connected to thesecond bracket proximate a first end of the second bracket. In anembodiment, the second end of the turnbuckle is connected to the secondbracket proximate a second end of the second bracket. In an embodiment,rotation of the frame of the turnbuckle causes the second end of thefirst bracket and the second end of the second bracket to move arcuatelythereby causing the first and second lock pins connected proximate thefirst ends of the first and second brackets to rotate. In an embodiment,when rotated, the first and second lock pins apply force at the interiorsurfaces of the first and second apertures in opposite directions toimmobilize the lock pins in the respective apertures.

In an embodiment, the pin support comprises fasteners for securing thepin support on the main bearing supports or main bearing supportextensions. In an embodiment, the pin support comprises a beam. In anembodiment, the fasteners comprise first and second clamps situatedproximate ends of the beam. In an embodiment, the clamps are mountableon the main bearing supports or main bearing support extensions. In anembodiment, the support aperture for each lock pin is a through aperturethrough the beam between the hub-facing face and a gearbox-facing faceof the beam. In an embodiment, the lock pin is inserted through thethrough aperture so that the cammed portion protrudes from thehub-facing face and the first cylindrical portion protrudes from thegearbox-facing face. In an embodiment, the pin support is supportable onmain bearing supports or main bearing support extensions in the nacelle.Being mountable on the main bearing supports or main bearing supportextensions, the rotor lock is useable to lock the rotor irrespective ofthe turbine component to be replaced or repaired.

Further features will be described or will become apparent in the courseof the following detailed description. It should be understood that eachfeature described herein may be utilized in any combination with any oneor more of the other described features, and that each feature does notnecessarily rely on the presence of another feature except where evidentto one of skill in the art.

BRIEF DESCRIPTION OF THE DRAWINGS

For clearer understanding, preferred embodiments will now be describedin detail by way of example, with reference to the accompanyingdrawings, in which:

FIG. 1 depicts a rear perspective view of an interior of a nacelleshowing existing rotor hub flange, main bearing, main bearing supportsand main rotor shaft of a wind turbine;

FIG. 2 depicts a rear perspective view of the nacelle of FIG. 1 furthershowing a rotor lock of the present invention supported on the mainbearing supports;

FIG. 3 depicts a side perspective view of FIG. 2 ;

FIG. 4 depicts a rear view of FIG. 2 ;

FIG. 5 depicts FIG. 2 with the rotor lock in a fully open configuration;

FIG. 6 depicts a front view of FIG. 5 ;

FIG. 7 depicts a top view of FIG. 5 ;

FIG. 8 depicts FIG. 2 with the rotor lock in a fully closedconfiguration;

FIG. 9 depicts a front view of FIG. 8 ;

FIG. 10 depicts a rear perspective view of the rotor lock shown in FIG.2 ;

FIG. 11 depicts a rear view of the rotor lock of FIG. 10 ;

FIG. 12 depicts a top view of the rotor lock of FIG. 10 ;

FIG. 13 depicts a rear view of a rotor lock main disk of the rotor lockof FIG. 10 ;

FIG. 14 depicts a top view of the rotor lock main disk of FIG. 13 ;

FIG. 15 depicts a rear perspective view of a rotor lock pin of the rotorlock of FIG. 10 ;

FIG. 16 depicts a front view of the rotor lock pin of FIG. 15 ;

FIG. 17 depicts a top view of the rotor lock pin of FIG. 15 ;

FIG. 18 depicts a rear perspective view of a rotor lock pin bracket ofthe rotor lock of FIG. 10 ;

FIG. 19 depicts a side view of the rotor lock pin bracket of FIG. 18 ;and,

FIG. 20 depicts a rear view of the rotor lock pin bracket of FIG. 18 .

DETAILED DESCRIPTION

Referring to FIG. 1 , a nacelle of a wind turbine houses a bed plate101, a gear box 102, a main rotor shaft 103, a main bearing 104, mainbearing supports 105 and a rotor hub flange 106 having a plurality ofrotor lock apertures 107 (only one labeled), as is known in the priorart.

Referring to the Figures, a rotor lock 1 of the present invention ismountable on main bearing support extensions 5, the main bearing supportextensions 5 being brought up to the nacelle and mounted on the mainbearing supports 105 to provide locations on which cranes and otheraccessories may be temporarily mounted in the nacelle. The rotor lock 1comprises a main disk, for example a beam 10 as illustrated althoughother forms of main disk are possible, having a longitudinal axis thatextends laterally across the nacelle between the main bearing supports105 over the rotor bearing 104 proximate to and to a rear face of therotor hub flange 106. The beam 10 comprises spaced-apart eye plates 13for connection to a lifting apparatus to permit lifting the rotor lock 1up to the nacelle and positioning the rotor lock 1 on the main bearingsupport extensions 5.

Ends of the beam 10 are equipped with clamps 20 that secure the rotorlock 1 to protrusions extending forwardly from the main bearing supportextensions 5. Each clamp 20 comprises a bolt plate 21 and a shim plate22 between which the protrusion is clamped, and a plurality of bolts 23inserted through bolt holes 24 extending between top and bottom surfacesof the beam 10. The bolts 23 extend through corresponding apertures in apressure plate 25 on the top surface of the beam 10, and extend intothreaded apertures in a top surface of the bolt plate 21. Tightening thebolts 23 provides the pressure to clamp the protrusions between the boltplates 21 and shim plates 22 to secure the rotor lock 1 on the mainbearing support extensions 5. The rotor lock 1 may be dismounted byloosening the bolts 23.

The beam 10 comprises two spaced-apart pin support apertures 12, whichare aligned with two corresponding rotor lock apertures 107 in the rotorhub flange 106 when the rotor lock 1 is mounted on the main bearingsupport extensions 5. Lock pins 30 extend through the pin supportapertures 12, one end of each lock pin 30 protruding rearwardly from arear face of the beam 10 and another end of each lock pin 30 protrudingforwardly from a front face of the beam 10. Each pin 30 comprises afirst portion 31 and a second portion 32. The first portion 31 occupiesand is rotatable within the pin support aperture 12, and protrudesrearwardly from the rear face of the beam 10. The second portion 32protrudes forwardly from the front face of the beam 10. With the rotorlock 1 mounted on the main bearing support extensions 5, the secondportion 32 extends into one of the rotor lock apertures 107 in the rotorhub flange 106. While two lock pins are illustrated, one lock pin ormore than two lock pins may be employed instead. Shims between bottomsof the bolt plates 21 of the clamps 20 and the main bearing supportextensions 5 may be used to adjust tightness of the lock pins 30 in therotor lock apertures 107.

As best seen in FIG. 16 and FIG. 17 , the first portion 31 has a largerdiameter than the second portion 32. Further, a center C32 of the secondportion 32 is offset from a center C31 of the first portion 31 so thatcentral axes A31, A32 of the first and second portions 31, 32,respectively, are parallel but not colinear. When the lock pin 30rotates, the lock pin 30 rotates about the axis through C31 with theaxis through C32 also rotating about the axis C31. Perimeters of thefirst and second portions 31, 32 may share a common point P, but theperimeter of the second portion 32 does not extend beyond the perimeterof the first portion 31. While the two perimeters may share a commonpoint, in some embodiments the perimeter of the second portion 32 may bewholly inside the perimeter of the first portion 31. When the lock pin30 is rotated the second portion 32, the center C32 follows a path thatdescribes an arc around the center C31. When the second portion 32extends into one of the rotor lock apertures 107, rotation of the lockpin 30 also results in movement of the second portion 32 laterallyinside the rotor lock aperture 107. Lateral movement of the secondportion 32, i.e. camming action, brings an outside surface 33 of thesecond portion 32 into contact with an inner surface 107 a (see FIG. 1 )of the rotor lock aperture 107. Maintaining contact between the outsidesurface 33 of the second portion 32 and the inner surface 107 a of therotor lock aperture 107 arrests rotation of the rotor thereby lockingthe rotor in place. The rotor can be released by reversing the rotationof the lock pin 30 to disengage the outside surface 33 of the secondportion 32 from the inner surface 107 a of the rotor lock aperture 107.While the first and second portions 31, 32 of the lock pin 30 are shownas cylinders, the second portion 32 could be some other shape, forexample elliptical, that can be inserted into the rotor lock aperture107 and engage the inner surface 107 a of the rotor lock aperture 107when the lock pin 30 is rotated.

The lock pins 30 may be rotated by a pin rotating mechanism 40comprising a force applicator, for example a turnbuckle 41 asillustrated or some other device for applying force such as a lever or acrank. The turnbuckle 41 comprises a frame 42 having threaded aperturesat each end through which jaw bolts are threaded. The jaw bolts arepivotally connected to ends of lock pin brackets 44, the lock pinbrackets 44 connected by bolts 45 inserted through bracket apertures 46to the lock pins 30. The bolts 45 are threaded into bolt holes 36 inrear ends 37 of the first portions 31 of the lock pins 30. For greatersecurity, the rear ends 37 of the first portions 31 of the lock pins 30comprise channels 38 sized to snugly fit the lock pin brackets 44therein.

Rotation of the frame 42 of the turnbuckle 41 causes the jaw bolts toextend or retract thereby causing the ends of the lock pin brackets 44to translate, which in turn causes the lock pins 30 to rotate. FIG. 5 toFIG. 7 show the rotor lock 1 in a fully open configuration where theends of the lock pin brackets 44 are pushed slightly but not fully apartfrom vertical, whereas FIG. 8 and FIG. 9 show the rotor lock 1 in afirst fully closed configuration where the ends of the lock pin brackets44 are pulled together from the vertical. A second fully closedconfiguration occurs when the lock pin brackets 44 are pushed fullyapart from the vertical. As best seen in FIG. 6 , in the fully openconfiguration, it is possible to insert and retract the lock pins 30into and out of the rotor lock apertures 107, and there is sometolerance between the outside surfaces 33 of the second portions 32 ofthe lock pins 30 and the inner surfaces 107 a of the rotor lockapertures 107 so that the rotor is capable of some, if only a smallamount of, rotational movement. As best seen in FIG. 9 , in the firstfully closed configuration, the outside surfaces 33 of the secondportions 32 of the lock pins 30 are engaged with the inner surfaces 107a of the rotor lock apertures 107 so that the rotor cannot rotate, theturnbuckle 41 holding the ends of the lock pin brackets 44 in place toprevent the lock pins 30 from rotating even a small amount. In the firstfully closed configuration, force is applied against the inner surfaces107 a of the rotor lock apertures 107 by the outside surfaces 33 of thesecond portions 32 of the lock pins 30 in opposite directions. As seenin FIG. 9 , the second portion 32 of the right-side lock pin 30 isengaged with the inner surface 107 a of the right-side rotor lockaperture 107 on the right side, while the second portion 32 of theleft-side lock pin 30 is engaged with the inner surface 107 a of theleft-side rotor lock aperture 107 on the left side. The forces appliedby the lock pins 30 in the rotor lock apertures 107 are therefore in theopposite direction away from each other. In the second fully closedconfiguration, the second portion 32 of the right-side lock pin 30 isengaged with the inner surface 107 a of the right-side rotor lockaperture 107 on the left side, while the second portion 32 of theleft-side lock pin 30 is engaged with the inner surface 107 a of theleft-side rotor lock aperture 107 on the right side. The forces appliedby the lock pins 30 in the rotor lock apertures 107 are therefore in theopposite direction toward each other. The first fully closedconfiguration is preferred in use.

The novel features will become apparent to those of skill in the artupon examination of the description. It should be understood, however,that the scope of the claims should not be limited by the embodiments,but should be given the broadest interpretation consistent with thewording of the claims and the specification as a whole.

The invention claimed is:
 1. A lock for preventing rotation of a rotorof a wind turbine, the lock comprising: a pin support supportable in anacelle of the wind turbine, the pin support having a hub-facing faceproximate a rotor hub of the wind turbine when the pin support issupported in the nacelle; a rotatable lock pin rotatably mounted on thepin support, the lock pin having a cammed portion extending away fromthe hub-facing face of the pin support toward the hub, the lock pininserted into a complementary rotor lock aperture on the rotor hub whenthe pin support is supported in the nacelle, rotation of the lock pincausing engagement of an exterior surface of the cammed portion with aninterior surface of the complementary aperture to immobilize the lockpin against the interior surface of the complementary aperture toprevent relative motion between the lock pin and the complementaryaperture to prevent rotation of the rotor, the lock pin comprising afirst cylindrical portion rotatably mounted through a support aperturein the pin support, the first cylindrical portion having a first centralaxis, the cammed portion of the lock pin being a second cylindricalportion of the lock pin having a second central axis, the secondcylindrical portion having a different diameter than the firstcylindrical portion, the second cylindrical portion extending from anend of the first cylindrical portion such that the first and secondcentral axes are not colinear; a force applicator comprising aturnbuckle for rotating the lock pin; and, a lock pin bracket, the lockpin connected to the bracket proximate a first end of the bracket andthe force applicator connected to the bracket proximate a second end ofthe bracket, whereby rotation of the force applicator causes the secondend of the bracket to move arcuately thereby causing the lock pinconnected proximate the first end of the bracket to rotate.
 2. The lockof claim 1 further comprising fasteners for securing the pin support onmain bearing supports or main bearing support extensions.
 3. The lock ofclaim 1, wherein the pin support is supportable on main bearing supportsor main bearing support extensions in the nacelle.
 4. A lock forpreventing rotation of a rotor of a wind turbine, the lock comprising: apin support supportable in a nacelle of the wind turbine, the pinsupport having a hub-facing face proximate a rotor hub of the windturbine when the pin support is supported in the nacelle; first andsecond rotatable lock pins rotatably mounted on the pin support, each ofthe lock pins having a cammed portion extending away from the hub-facingface of the pin support toward the hub, the lock pins inserted intocomplementary first and second rotor lock apertures, respectively, onthe rotor hub when the pin support is supported in the nacelle, rotationof the lock pins causing engagement of exterior surfaces of the cammedportions with interior surfaces of the complementary apertures toimmobilize the lock pins against the interior surfaces of thecomplementary apertures to prevent relative motion between the lock pinsand the complementary apertures to prevent rotation of the rotor; and, asingle force applicator for rotating both of the lock pinssimultaneously.
 5. The lock of claim 4, wherein the first and secondlock pins apply force at the interior surfaces of the first and secondcomplementary apertures in opposite directions to immobilize the lockpins in the respective apertures.
 6. The lock of claim 4, furthercomprising first and second lock pin brackets, the first lock pinconnected to the first bracket proximate a first end of the firstbracket, and a first end of the force applicator connected to the firstbracket proximate a second end of the first bracket, the second lock pinconnected to the second bracket proximate a first end of the secondbracket, and a second end of the force applicator connected to thesecond bracket proximate a second end of the second bracket, wherebyrotation of the force applicator causes the second end of the firstbracket and the second end of the second bracket to move arcuatelythereby causing the first and second lock pins connected proximate thefirst ends of the first and second brackets to rotate.
 7. The lock ofclaim 6, wherein: each lock pin comprises a first cylindrical portionrotatably mounted through a respective support aperture in the pinsupport, the first cylindrical portion having a first central axis; and,the cammed portion of each lock pin is a second cylindrical portion ofthe lock pin having a second central axis, the second cylindricalportion having a different diameter than the first cylindrical portion,the second cylindrical portion extending from an end of the firstcylindrical portion such that the first and second central axes are notcolinear.
 8. The lock of claim 7, wherein, for each lock pin, the secondcylindrical portion has a smaller diameter than the first cylindricalportion.
 9. The lock of claim 7, wherein the pin support comprises: abeam; and, first and second clamps situated proximate ends of the beam,the clamps mountable on main bearing supports or main bearing supportextensions, whereby the support aperture for each lock pin is a throughaperture through the beam between the hub-facing face and agearbox-facing face of the beam, each lock pin inserted through acorresponding one of the through apertures so that the cammed portionprotrudes from the hub-facing face and the first cylindrical portionprotrudes from the gearbox-facing face.
 10. The lock of claim 4, whereinthe pin support is supportable on main bearing supports or main bearingsupport extensions in the nacelle.